System for manufacture of foam sheets rigidized with polymer infiltration

ABSTRACT

A rigid polymer porous material sheet is produced by feeding a slurry of polymer mixture comprising ultrafine polyvinylchloride particle, non-phthalate plasticizer, foaming agent and thermal stabilizer, polymer chips, fillers and fire retardant chemicals into a heated mold and pressing the mixture with high applied pressure. The temperature of the mold is below 190° C. to soften the polymer mixture and decompose the foaming agent forming the closed cell polyvinylchloride foam with 10 to 40% density with closed air cells. The thermal resistance of the rigid polymer porous sheet and sound attenuation properties are significantly improved. The rigid polymer porous sheet can be bent at sharp angles without crack formation facilitating its use as wall boards. The sheets produced may be embossed or molded to produce decoration boards, advertising boards, cabinet doors and furniture with decorative features. They can also be used in aeronautical applications as acoustic thermal insulation systems.

This application claims the benefit of Provisional Application No.62/174,462 filed Jun. 11, 2015, entitled “SYSTEM FOR MANUFACTURE OF FOAMSHEETS RIGIDIZED WITH POLYMER INFILTRATION” which, in turn, claims thebenefit of Provisional Application No. 62/172,059 filed Jun. 6, 2015,entitled “SYSTEM FOR MANUFACTURE OF FOAM SHEETS RIGIDIZED WITH POLYMERINFILTRATION” which, in turn, claims the benefit of ProvisionalApplication No. 62/177,656 filed Mar. 20, 2015 entitled “SYSTEM FORMANUFACTURE OF FOAM SHEETS RIGIDIZED WITH POLYMER INFILTRATION”, thedisclosures of which are hereby incorporated by reference thereto intheir entirety.

FIELD OF THE INVENTION

The present invention relates to manufacture of rigid foam industrialsheets with applications not limited to building materials, such as wallboard, tile, lumber, a wide variety of wood and wood related products,and the like; and, more particularly to a system which forms plain ordecorative low density high strength high modulus rigid sheets by a hightemperature high pressure molding process forming polyvinyl chloridepolymer foams that incorporate polymer additives.

DESCRIPTION OF THE PRIOR ART

Decoration boards presently available in the market include, forexample, wooden board, particleboard, oriented strand board (“OSBboard”), plywood, density board, fiber composite board, PVC foamingboard, and fireproof board. Wooden board, OSB board, particleboard,density board, and fiber composite board exhibit very low anti-flamingand fire resistant performance. They are not waterproof or moistureproof and, consequently, enjoy somewhat limited application. Fireproofboard is generally a sandwich board with 3 layers. Metal boards(aluminum boards, stainless steel boards, colored iron boards, titaniumzinc boards, titanium boards, copper boards, etc.) comprise a metallicsurface and bottom layers, and halogen free, anti-flaming inorganiccompositions comprising the middle layer. This hot-pressed compositeboard exhibits good anti flaming and fire resistant performance, but itis heavy, expensive, and is not waterproof.

Numerous prior art patents and disclosures relate to formation of sheetmaterial from polymeric foam. Specifically these polymeric foams are notinfiltrated with polymers to produce plain or decorative rigid sheetsfor use in structural or decorative building materials and otherapplications.

U.S. Pat. No. 4,284,681 to Tidmarsh, et al. discloses composite sheetmaterial. The composite material comprises a layer of highly-plasticizedpolyvinylchloride, comprising 15 to 45% of polyvinylchloride and 55 to85% by weight of a plasticizer, a fibrous backing, and an intermediatelayer of a polymeric material between the polyvinylchloride layer andthe backing. Various adhesives may be used to stick the compositematerial to substrates such as walls, ceilings, and floors. If theintermediate layer is not completely impervious to the plasticizer inthe highly-plasticized layer, then the adhesive should preferably resistplasticizer migration. This composite material is a coating layer on astructural object, but is by itself not a structural material.

U.S. Pat. No. 4,510,201 to Takeuchi, et al. discloses a polyvinylchloride resinous molded sheet product. The polyvinyl chloride resinouscompositions containing cellular fillers such as Silus Balloon andpearlite and molded products are prepared by subjecting the compositionsto heating at an increased pressure. The molded products may be combinedwith a core layer such as a non-woven fabric and a victria lawn, afoamed layer such as PVC paste resinous foam, and a surface layer suchas a non-foamed synthetic resin, and molded into laminated sheetproducts. Those are made lighter and superior in soundproof andadiabatic effects, bending strength, dry touchness, water resistance,dimensional stability, cold resistance and the like. The sheet productis usable a floor coverings and other applications. This is a multilayerPVC molded sheet and is not a low-density single layer PVC foam.

U.S. Pat. No. 5,300,533 to Dahl, et al. discloses a method forproduction of crosslinked plastic foam. This method produces foamedcross linked vinyl chloride containing polymer wherein a blowing agentis added to a copolymer produced by a copolymerization of a monomercomposition comprising vinyl chloride and glycidyl containing monomer.Foaming of the copolymer occurs by the decomposition products of theblowing agent or decomposition products of reaction from a chemicallyreactive azodicarbonamide blowing agent with epoxy groups of thecopolymer. The glycidyl containing monomer is a glycidyl acrylate ormethacrylate or butylacrylate. It is possible to crosslink foamed vinylchloride polymers through an addition of epoxy groups which areintroduced via a copolymer. The crosslinking takes place by help of thedecomposition products from the blowing agent. This requires formationof copolymer of vinyl chloride and glycidyl methacrylate to be producedby suspension-, microsuspension-, emulsion- or mass polymerization.

U.S. Pat. No. 5,695,870 to Kelch et al. discloses laminated foaminsulation board of enhanced strength. This laminated insulating foamboard comprises a panel composed of a plastic foam material thickness ofabout ¼ inch to about 1 inch; and first and second thermoplastic facerfilms, each adhered to primary, opposite surfaces of the panel, thefacer films being biaxially oriented, the facer films each having athickness of about 0.35 to about 10.0 mils. The board produced has anultimate elongation of less than 200 percent in both machine andtransverse directions and a yield tensile strength of at least 7,000pounds per square inch in both machine and transverse directions with a1 percent secant modulus of at least 200,000 pounds per square inch inboth machine and transverse directions. The laminated foam insulation isa panel of extruded polystyrene plastic foam material and is not apolyvinylchloride foam.

U.S. Pat. No. 6,254,956 to Kjellqvist et al. discloses a floor, wall orceiling covering. This floor, wall or ceiling covering comprises one ormore substantially random interpolymers prepared by polymerizing one ormore α-olefin monomers with one or more vinylidene aromatic monomersand/or one or more hindered aliphatic or cycloaliphatic vinylidenemonomers, and optionally with other polymerizable ethylenicallyunsaturated monomer(s). The floor, wall or ceiling covering has a goodbalance of properties, such as sufficient flexibility and conformabilityto uneven or contoured surfaces for efficient application to floors,walls, or ceilings, sufficient scratch resistance, sufficientindentation resistance, indentation recovery and/or sufficient abrasionresistance. The floor, wall or ceiling covering is made by polymerizingone or more polymers. The floor wall or ceiling covering is not apolyvinylchloride foam product made by hot pressing a slurrycomposition.

U.S. Pat. No. 8,097,658 to Rosthauser discloses a process for theproduction of medium density decorative molded foams having good fireretardant properties with reduced mold times, fire retardantcompositions and foams produced by this process. This fire-resistant,medium density molded polyurethane foam is said to be removed from amold in substantially shorter times than previously possible. Thesereduced de-mold times are achieved by including a solid flame retardantcomposition in the polyurethane foam forming composition. This solidflame retardant composition includes a melamine coated ammoniumpolyphosphate and zinc borate. The process uses polyurethane foamforming a reactive mixture and is not indicated to be a low-densitypolyvinylchloride foamed structural material.

U.S. Patent Application No. 20060264523 discloses polyvinyl chloridefoams. The polyvinyl chloride foams exhibit improved mechanical strengthand non-flammability. Microcellular polyvinyl chloride foams having theclosed cell structure have a high foaming efficiency even with a smallamount of a foaming agent. The polyvinyl chloride foams comprise vinylchloride resin-layered silicate nanocomposites in which the layeredsilicates are dispersed onto the vinyl chloride resins containingfoaming agents. The foaming of the composition is accomplished bymechanical action of carbon dioxide injection and the specific gravityof foam formed is very high, greater than 1 gram/cc.

U.S. Patent application No. 20130310471 discloses the use of di(isononyl) cyclohexanoate (DINCH) in expandable PVC formulations. Theinvention relates to a foamable composition containing at least onepolymer selected from the group consisting of polyvinyl chloride,polyvinylidene chloride, polyvinyl butyrate, polyalkyl (meth) acrylateand copolymers thereof. The plasticizer used is diisononyl1,2-cyclohexanedicarboxylate (DINCH) and diisononyl (ortho)phthalate(DINP) is a plasticizer that has chemical hazards as indicated in theU.S. Consumer Product Safety Commission athttps://www.csc.gov/PageFiles/98260/dinp.pdf. The foam former ofazodicarbonamide. Foam stabilizer is ZnO which acts as a kicker for thedecomposition of azodicarbonamide. The polymeric composition is formed alow viscosity plastisol and has to be applied to a support during overcuring. Accordingly, the '471 application does not produce free-standinglow density PVC sheets.

Chinese patent application #CN103265776A to Hou Yu Hung Yi-Draindiscloses an eco-wood and its preparation method. The ecological woodprovides a waterproof, moisture resistant material that does not containformaldehyde, toluene and other harmful substances. The eco-wood isflame-retardant with small amount of smoke and has ductility, toughness,good impact resistance and acid corrosion resistance. The preparationmethod for the long life ecological wood comprises the followingcomponents by weight: Chlorine vinegar copolymer resin: 60 to 70, Impactmodifiers (Nitrile butadiene rubber): 9-11, Plant fiber: 20 to 30,Coupling agent (titanate): 1 to 3, Smoke suppressant: 10-20, ActivatedClay: 5-15, Lubricants (polyethylene wax): from 0.5 to 1.5, Activator(ZnO): 4-6, Green flame retardant (ammonium phosphate): 8-10, ThermalStabilizer (Ca and Zn compounds): 4-8, Odorless crosslinking agent: 0.5to 1.5, Foaming agent (AC-3000 which is azodicarbonamide): 1 to 5,Desmopressin agent: 1 to 5. The preparation method includes plant fiberpretreatment, kneading mixer, open mill soak, the film machine the film,closed-cell foam mold, cooling stable pattern. The composition of theeco-wood comprises plant fibers and relies for toughness thepolyvinylchloride resin which contains polyvinyl acetate and otherswithout the use of plasticizers such as phthalates. The amount ofcopolymer addition is not specified accordingly, the flexibility of thecoo-wood is unclear.

The web page athttps://vtechworks.lib.vt.edu/bitstream/handle/10919/42108/McGrane2.pdf?sequence=1&isAllowed=ydiscloses Vacuum Assisted Resin Transfer Molding of Foam SandwichComposite Materials. This method relates to resin transfer molding ofdry carbon preforms with polymethacrylimide foam cores to producecomposite sandwich structures. This disclosure does not produce apolymer sheet hot pressed to produce a rigid plain or decorativestructural sheet.

The publication “Effect of additives on flexible PVC foam formation” inJournal of Materials Processing Technology 2007.04.123 discusses theeffects of Ca/Zn stearate and organotin heat stabilizers and zeolite,CaCO3, cellulose and luffa flours fillers, and their concentrations(2.5, 5, 10 and 20% by weight) on production of flexible PVC foams bychemical blowing agent. Azodicarbonamide was investigated. Thestabilizer decreases the decomposition temperature of azodicarbonamidefrom 200° C. to PVC processing temperature of 160 to 190

https://en.wikipedia.org/wiki/1,2-Cyclohexane_dicarboxylic_acid_diisononyl_ester1,2-Cyclohexane dicarboxylic acid diisononyl ester is a plasticizer forthe manufacture of flexible plastic articles in sensitive applicationareas such as toys, medical devices and food packaging. From a chemicalpoint of view it belongs to the group of aliphatic esters. In 2002, BASFstarted selling 1,2-cyclohexane dicarboxylic acid diisononyl ester underthe tradename of Hexamoll DINCH as an alternative for phthalateplasticizers. [3]

http://www.sustainableproduction.org/downloads/PhthalateAlternatives-January2011.pdf

TABLE 2 Alternative Plasticizers DOS: Dioctyl sebacate, TXIB:2,2,4-trimethyl 1,3-pentanediol diisobutyrate, TEHPA: Tri(2-ethylhexyl)phosphate, DEHPA: Di(2-ethylhexyl) phosphate, Eastman 168:bis(2-ethylhjexyl)- 1,4-benzenedicarboxylate, TETM: Tri-2-ethylhexyltrimellitate, ESBO: Epoxidized soybean oil, DOTP: Dioctyl terephthalate.DINCH: Di-isononylcyclohexane-1,2-dicarboxylate

Based on the foregoing, there exists a need in the art for an easy touse method for manufacturing building materials in the form of plain ordecorative rigid structural sheets that exhibit flame resistance,enhanced insulation and mold-free properties.

SUMMARY OF THE INVENTION

The present invention provides a rigid polyvinylchloride based foamsheet that is especially well suited for, but not limited to, buildingconstruction. The sheets have a density ranging from 0.12 to 0.66grams/cc, which is about 10% to 40% of solid flexible PVC (whichtypically exhibits a density of 1.1 to 1.35 grams/cc). Sheet formedaccording to subject invention has a very large number of closedmicrocells ranging in dimension from 10 to 70 micro meters. The cellshave a cell wall of polyvinylchloride based polymer. These sheets alsohave extremely small sized uniformly distributed closed cells of airpockets that enhance thermal insulation properties and provide soundattenuation characteristics. The density of the sheets produced dependson the composition of the PVC resin, mold fill quantity, and thepressure and temperature applied during sheet formation. Also providedis a method for manufacturing rigid polymer porous material sheets.

The method of production of polyvinylchloride based sheets usesultrafine particles of virgin polyvinyl chloride synthesized bysuspension-, microsuspension-, emulsion- or mass polymerization. ThesePVC particles in stage I are about 4 manometers, agglomerate in stage IIto micro granules of 1-2 micrometers and a number of micro granulesagglomerate in stage III to a particles ranging typically in size from100 to 150 micrometers. These ultrafine homopolymer of polyvinylchlorideand copolymers of polyvinylchloride with polyvinyl acetate are freeflowing and they become raw materials for making the slurry for formingthe sheets according to the subject invention. The K value of the PVCpolymer used has a value greater than 65 representing a molecular weightgreater than 60,000. The amount of polyvinyl acetate present in thecopolymer has a strong influence on increasing the flexibility of thefinal product produced since polyvinyl acetate decreases the hardness,strength and modulus of the final sheet product and is maintained in therange of 2% to 30% of the copolymer.

In order for the final PVC sheet formed to have adequate flexibility,plasticizers need to be incorporated during the sheet formation process.The plasticizers are chemical species, which dissolve into the PVCcomposition chains and promote flexing at the molecular level byscreening or hinge mechanism. A number of plasticizers are known forexample, derivatives of phthalic acid such as diisodecyl phthalate,derivatives of phosphoric acid such as tricresyl phosphate, derivativesof adipic acid such as dioctyl adipate and diisodecyl adipate,derivatives of azelaic acid such as dioctyl azelate, derivatives ofbenzoic acid such as diethylene glyco dibenzoate. epoxy plasticizer,derivatives of citric acid such as tributyl citrate, derivatives ofsebacic acid such as dioctyl sebacate, derivatives of trimellitic acidsuch as trioctyl trimellitate; derivatives of sulfonic acid, fatty acidesters, glycerine derivatives, chlorinated paraffin, chlorinateddiphenyls, derivatives of pyromellitic acid and polyester plasticizers.Due to the recently discovered biohazard of phthalates the subjectinvention uses phthalate-free plasticizers such as diisononyl1,2-cyclohexanedicarboxylate (DINCH). Other phthalate-free plasticizersare DOS: Dioctyl sebacate, TXIB: 2,2,4-trimethyl 1,3-pentanedioldiisobutyrate, TEHPA: Tri (2-ethylhexyl) phosphate, DEHPA: Di(2-ethylhexyl) phosphate, Eastman 168: bis(2-ethylhexyl)-1,4-benzenedicarboxylate, TETM: Tri-2-ethylhexyltrimellitate, ESBO: Epoxidized soybean oil, DOTP: Dioctyl terephthalate.A subsequent reduction of plasticizer incorporation will result inincreased rigidity of the sheet.

Formation of a foamed product requires a foaming agent that producesfine pores with the mold PVC based sheet. The foaming agent decomposesat a decomposition temperature producing a large volume of gaseousreaction product. A number of foaming agents for use in foamed PVCproduction are known and they include for example azodicarbonamide,dinitrosopentamethylenetetramine, p-toluenesulfonyl hydrazide, and4,4′-oxybis(benzne sulfonyl hydrozide. The preferred foaming agent isazodicarbonamide since it has a decomposition temperature of about 215to 219° C. This decomposition temperature is slightly greater than thesoftening temperature of PVC compositions, which is typically in therange of 170 to 190° C. A kicker compound such as ZnO may be used tobring the decomposition temperature of azodicarbonamide to the softeningtemperature range of PVC resins used.

The PVC particles in the 100 to 150 micrometer range incorporate all theadditives, including the plasticizers and foaming agents, and are wettedby water assisted by anionic surfactants or by isopropyl alcohol formingslurry. This slurry is loaded into a mold and heated when it is underpressure between two plates. The drying of the slurry brings the PVCcomposition particles in close contact with each other due to surfacetension and they join together when the softening point of the PVC andat the same time, the foaming agent decomposes and release a largeamount of gas creating sa low density PVC foam. The distribution ofporosity in the molded PVC sheet is controlled by the particle size ofthe foaming agent and its distribution in the slurry.

The air cells formed have to be stabilized so that they remain until thepolyvinylchloride polymer sets. The stabiles are typically organic orinorganic compounds such as barium/zinc, calcium/zinc or organ tinstabilizers

The present invention produces two types of PVC sheets. The first typeuses homopolymer of PVC compacted using sufficient diisononyl1,2-cyclohexanedicarboxylate (DINCH) plasticizer producing a flexibleproduct, yet and does not have any biohazard of phthalates. The secondtype of PVC uses copolymers of PVC with 2 to 30% polyvinyl chloride. Dueto enhanced flexibility of polyvinylacetate containing PVC composition,a lesser amount of diisononyl 1,2-cyclohexanedicarboxylate (DINCH)plasticizer is needed.

Applications of the present invention also contemplate use inaeronautical technologies, including noise cancelling aviationinsulating systems. These systems comprise an insulation material, whilealso uniquely providing enhanced acoustic properties minimize the cabinsound from the exterior of an aircraft. Owing to its physicalproperties, the subject material is ideal for use as an aircraftthermal/acoustic insulation material. Both thermal and acousticalinsulation is required on passenger aircrafts. Historically bothfunctions have been provided by the same material system, which hasmostly been fiberglass batting encapsulated in a plastic pillowcasecovering. Covering plastics have been predominantly PET (such aspolyethylene terephthalate, commonly sold under the trade name Mylar byDuPont), and a lesser quantity of polyvinyl fluoride (PVF), (commonlysold under the trade name Tedlar by DuPont), and a polyimide film(commonly sold under the trade name Kapton by DuPont) has been used. Useof the material of the subject invention provides the ability to replaceat least some (if not all) of the material currently used with aninnermost layer sheet thereby increasing the thermal properties, whilealso improving the acoustics within the air plane cabin. What is more,use of the subject material results in cost savings as well as a slightdecrease in weight, without being bound by theory, which in turndecreases fuel costs.

Typically, the thermal environment outside an airplane produces fuselageskin temperatures from about −60 F when in-flight at altitude to about+160 F when parked in direct sunlight in the desert. The amount ofinsulation needed for the air conditioning/heating system toeconomically produce comfortable cabin temperatures varies with airplanetype and location. However, except for a few places such as the crownarea over the aft passenger cabin and the lower fuselage area below thepassenger floor, acoustic requirements predominate. Therefore, exceptfor those places, the amount of insulation present exceeds that neededfor thermal requirements.

Regarding acoustics, the outside noise is generated by aerodynamics andengines. Insulation is used to attenuate outside noise to allowreasonable levels of comfort and verbal communication inside thepassenger cabin and flight deck. The acoustic attenuation needed variesfrom airplane to airplane, but is generally substantial and insulatingmaterial of very high acoustic efficiency is used to minimize the amount(weight, volume) required. Fiberglass batting, using a very small fiberdiameter, is a highly efficient acoustic attenuator.

Currently, insulation using fiberglass batting will resist firepenetration in lower-intensity thermal environments. Cargo compartmentsare required to have liners that are fire barriers. In somecompartments, the thermal insulation lining the fuselage provides thefire barrier. For these areas, the requirement involves a Bunsen burnertest fiberglass batting easily passes. The FAA has released informationin press reports that it plans to propose a requirement that insulationbe resistant to burn through in an intense thermal environment like thatof a fuel-fed fire. All insulation material systems would have to beredesigned to meet this requirement.

Accordingly, the novel material of the subject invention providesimproved acoustical, thermal, and fire barrier functions while providingcost savings. As pointed out hereinabove, implementation of the materialof the subject invention provides the ability to replace at least some(if not all) of the fiber glass material currently used with aninnermost layer sheet near the interior of the cabin. This increases thethermal properties, while also improving the acoustics within the airplane cabin and improving fire retardation. Such improved acousticscreate an acoustic cocoon having noise deflection attributes. Any newinsulation materials system must not substantially exceed the weight ofexisting systems, which averages about 0.1 lb/sqft. Glass batting variesfrom 0.34 to about 1.5 lb/cuft, with lighter weights predominating.Batting thickness is about 5 inches in the crown area, 3 inches alongthe sides, and 1 inch below the passenger floor. Covering materialvaries from 0.5 to about 1.5 oz/sqyd, with 0.5 and 0.9 oz/sqydpredominating. Cost savings results as well as a alight decrease inweight, without being bound by theory, which in turn decreases fuelcosts.

The material of the subject invention not only exhibits optimal thermal,acoustic and fire retardation properties, but further does not absorblarge amounts of water, does not cause or promote corrosion to thealuminum fuselage structure of the air craft, nor is it electricallyconductive, or interfere with inspection of the fuselage structure forcorrosion, cracks, etc. In fact, the use of the material as a sheetprovides an easier viewing of the fuselage than currently utilizedplastic bagged fiber glass and other materials, all while providing acleaner, safer installation with environmentally sound properties.

The production of the rigid polymer porous material, or composite, sheetstarts with a mold filled with slurry of polyvinyl chloride basedpolymer material with plasticizers, foaming agents and other filleringredient mixed with an aqueous solution with anionic surfactants orisopropyl alcohol. The slurry compacts the liquid portion drains anddried, bringing the polyvinyl chloride fine particles in close contactwith each other, forming a film. The content of the mold are pressedunder high applied pressure and heating temperature sufficient to softenor melt the polyvinyl chloride composition while at the same timedecomposing the foaming agent releasing a large amount of gaseousdecomposition products within the mold. This draining step may beunnecessary, since the heating step automatically volatilizes the liquidportion of the slurry. The pressed sheet has a typical density rangingfrom 15% to 35% and contains fine dimension of air pockets or calls. Themold dimension may be any size, shape or curvature; but is typically aslarge as 1220 mm×2440 mm with a mold depth of 60 mm. Depending upon theamount of slurry poured into the mold the thickness of the sheetproduced varies. For example, 10 kilos of slurry can produce a sheetthat is 40 mm (1.57 inch) in thickness. If a 120 mm (4.72 inch) mold isused to produce an 80 mm (3.15 inch) board, then double the amount (20kilograms) of raw slurry is added to the mold. The mold is then heatedwhen under applied pressure. Changing the mold size will change thefinal size of board produced. In this process, there is no limit on thesize of the sheet produced since it only depends on the size of themold. The mold and the top plate may have embossed structures thatreplicate in the finished sheet product producing decorativeconstruction material sheets.

The polymer mixture used for the slurry of the rigid polymer poroussheet material has one or more of PVC (Polyvinyl chloride) and polyvinylacetate polymers and, in some cases, is a composite sheet also furthercomprises wood chips and fire retardant chemicals. These polymers meltbelow 190° C.

In one embodiment, the polymer porous sheet slurry comprises polymerparticles with additives as fillers and fire retardant chemicals. Themold with the slurry is optionally drained of the liquid ingredients andthe mold is heated to below 190° C. when under applied pressure. Theapplication of pressure and heat consolidates the slurry solidingredients creating a sheet that is porous with air holes which havefine dimension and the overall density of the sheet product isapproximately 10% to 40% of solid polyvinylchloride sheet depending onthe pressure and heat applied. The presence of closed cell air pocketsenhances the thermal resistance properties of the sheet material andexhibits high R values which are much greater than that available fortypical gypsum based construction sheets, plywood, lumber, OSB, fiberboard, particle board and the like. The sheets or lumber made by theprocess of the subject invention create wall boards, wall assemblysystems and other construction products that provide improved heatretention to the building envelope, which significantly improves thethermal efficiency of a home or business building by eliminating orgreatly reducing the phenomena known as thermal bridging, which occursin part through a phenomena known as the framing factor. The mold mayhave decorative features, which are replicated on the surface of therigid polymer porous material sheet. Impervious decorative sheets suchas Formica sheets, aluminum foil, and stainless steel sheet may be usedto cover the rigid polymer porous material sheet during the moldingstep.

In a second embodiment the polymer slurry mixture may be injected intothe mold in a manner similar to resin transfer molding and heated toprocessing temperature.

In a preferred embodiment, the rigid polymer porous material sheet ofthe present invention, comprises:

1) an oversized mold having the normal length and width of the sheet,but having a height typically twice the thickness of the intended sheet;

2) said mold being injected with a slurry polymer mixture and drained ofthe liquid ingredients of the slurry, and heated at temperatures to meltthe polymers in the polymer mixture;

3) said mold being heated to a temperature below 190° C. when the moldis pressurized compacting the polymer mixture in the mold to a densityranging from 10% to 40% with closed cells of air pockets present withinthe sheet formed;

4) said mold having decorative markings that are transferred to themolded rigid polymer porous material sheet;

whereby the compaction of the polymer mixture forming a sheet withclosed air cells imparts the sheet with thermal resistance and soundattenuation properties, so that the sheets may be used in buildingconstruction as well as decorative applications.

BRIEF DESCRIPTION OF THE DRAWING

The invention will be more fully understood and further advantages willbecome apparent when reference is had to the following detaileddescription of the preferred embodiments of the invention and theaccompanying drawing, in which:

FIG. 1a illustrates the process steps in the manufacture of the rigidpolymer porous material sheet;

FIG. 1b illustrates a graph showing the relationship between theFikentscher K value and the molecular weight of PVC polymers;

FIG. 2 is a micrograph of the rigid polymer porous material sheet; and

FIG. 3 illustrates thermal resistance or R value measurement procedure;

FIG. 4 illustrates hardness measurement of rigid polymer porous sheet;

FIG. 5 illustrates bend test measurement of the rigid polymer poroussheet;

FIG. 6a illustrates the thermal bridge;

FIG. 6b illustrates the energy lost through studs;

FIG. 7a illustrates the framing factor concept;

FIG. 7b illustrates the framing factor concept with an IR image;

FIG. 8 illustrates an embodiment of the invention wherein the rigidpolymer porous material sheet is used in an aviation acoustic thermalinsulation system; and

FIG. 9 illustrates a framed structure wherein a humidity expansion gapof ⅛″ has been eliminated.

DETAILED DESCRIPTION OF THE INVENTION

The polyvinylchloride used in the present invention is in the form of100 to 150 micrometer particles produced by suspension or emulsionpolymerization. The K value of the polyvinylchloride homopolymer orcopolymer with polyvinyl acetate has a K value greater than 65representing a molecular weight of 60,000 as shown in the graph in FIG.1b , showing a graph reproduced from PVC Plastics by W. V. Titow. A Kvalue of 50 is a low molecular weight soft PVC while a K value of 80 isa high molecular weight strong PVC.

When a plasticizer is added to the fine power of polyvinylchloride basedresin, it enters the resin molecule at the atomic level creating screensbetween polymer chains or hinge locations between polymer chainspromoting polymer flexibility. Since the polyvinylchloride foamsproduced have a very thin polymer layer surrounding the air cell, itrequires a great amount of flexibility to prevent crack propagation andfracture. Conventional phthalate plasticizers have been determined to bea biohazard according to U.S. Consumer Product Safety Commission athttps://www.cpsc.gov/PageFiles/98260/dinp.pdf. The present invention,accordingly, uses only non-phthalate plasticizers, such as DINCH.

A foaming agent is needed to allow the formation of a plurality ofmicron sized air cells to produce the low density polyvinylchloridepolymeric sheet. When the polymeric composition is heated in a mold, ata specific temperature the polymer softens. If the foaming agentreleases a large volume of gaseous decomposition products at the sametime when the polyvinylchloride resin softens, a closed mllmicrocellular structure is formed. While a number of foaming agents areavailable, their decomposition temperature does not match the softeningpoint of polyvinylchloride resin which is in the range of 170 to 190° C.Specifically, azodicarbonamide foaming agent has a decompositiontemperature of 215 to 219° C., but it may be bought down using a ZnOkicker. Using this combination micro fine cells are formed in the lowdensity polyvinylchloride sheet.

Another requirement for the formation of the microcellular sheet duringfoaming step requires the ultrafine particles of polyvinylchlorideparticle to touch each other, since the quantity of polyvinylchloride inthe sheet is quite small. This is accomplished by mixing the polyvinylultrafine particles along with additives with and anionic aqueoussolution of isopropyl alcohol forming a slurry. During drying of theslurry, the surface tension brings the polyvinylchloride particles closeto each other, forming a film.

The air cells formed have to be stabilized so that they remain until thepolyvinylchloride polymer sets. The stabiles are typically organic orinorganic compounds such as barium/zinc, calcium/zinc or organ tinstabilizers

The present invention uses two distinctly different low densitypolyvinylchloride sheets. The first embodiment uses fine particles ofpolyvinylchloride homopolymer in combination with a higher amount ofDINCH non phthalate plasticizer. A typical example of the polymer slurryused in the mold is shown below.

Suspension PVC K value 70 (S-PVC) 100.0 parts Calcium stearate 1.2 partsTin stabilizer 2.0 parts Azodicarbonamide 8.0 parts Zinc oxide 1.5 partsPolymethylmethacrylate 4.8 parts DINCH plasticizer 15.0 parts

The second example shown below using a polyvinylchloride copolymer anduses a lesser amount of DINCH plasticizer.

Suspension PVC/20% Polyvinylacetate K value 70 (S-PVC) 100.0 partsCalcium stearate 1.5 parts Tin stabilizer 2.0 parts Azodicarbonamide 8.0parts Zinc oxide 1.5 parts DINCH plasticizer 10.0 parts

This invention relates to a molding process for producing rigid polymerporous polyvinyl chloride based sheet material, or composite, sheet.Slurry of polymer powder with additives and fillers and fire retardantmaterial is fed to an oversized mold whose height is approximately twicethat of the sheet thickness desired while width and the length of themold are close to that of the desired dimensions of the sheet. Theliquid portion of the slurry is optionally drained and dried first andthe mold is heated to a temperature below 190° F. when the mold ispressurized by a die set. This application of pressure and temperatureforms the sheet with a density ranging from about 5% to 98%, andpreferably from about 10% to about 40%, of a solid polyvinyl chloridesheet with closed air cells finely distributed within the sheet. Thepresence of closed air cells enhances the thermal resistance of thesheet product as well as provide sound absorption characteristics. Thedie may have milled decorations, which are replicated in the finalproduct.

The rigid polymer porous sheet rated product has a low density, andwater does not penetrate the product. The polymer slurry mixture usedcomprises PVC (Polyvinyl chloride) and polyvinyl acetate polymers alongwith wood chip and flame retardant additives, depending on theapplication of the final product. External casing sheets may be used tocover the rigid polymer porous sheet during the heating and pressureapplication step to bond the encasing sheets thereto. The rigid polymerporous composite sheet is inherently fire retardant due to the usage ofPVC in the polymer infiltration composition to release chlorine andexpel oxygen near a flame, thereby extinguishing the flame.

The objective of the invention is to create a durable rigid polymerporous sheet, which may be painted and is useful as a building material.The process used herein is very reproducible and produces sheets withexceptional properties. It does not crack when bent 90 degrees or moreand is extremely shock absorbing even though it is rigid. Accordingly,the rigid polymer porous sheet is well suited for wall boards, lumberand wall assembly systems.

The rigid polymer filled foam composite is the newest constructionmaterial developed as detailed herein. The rigid polymer porouscomposite sheet is anti-flaming, fireproof moisture proof,anti-corrosion, termite proof; formaldehyde free. It exhibits a lowamount of smoke, and is highly resistant to flame penetration. Thesurface of the sheet can be treated by spray coating, and can be adheredto many kinds of materials. In combination, these features have made therigid polymer filled foam composite an excellent eco-green constructionmaterial.

The rigid polymer porous sheet can be used as a replacement for woodenboard; thus reducing deforestation, and protecting the environment. Atthe same time, it is water proof; moisture proof; sound proof; vibrationabsorbing, resistant to acid and alkali, resistant to climate ageing,anti-flaming and fire proof. In these aspects, the rigid polymer filledfoam material sheet is superior to all other building materials.

Different kinds of materials are added into the rigid polymer filledfoam material sheet for different purposes:

-   -   1. For wood frame construction, wall, floor, and ceiling        assemblies, home decoration and furniture applications, large        amount of plant fibers (such as wood chips, husk of rice, etc.)        are added, to increase the hardness and nail holding ability;    -   2. For application in cars, yachts and ships, aircrafts, and        bullet trains, and application as embossing materials, thermal        preservation materials, nitrile butadiene rubber (NBR) is added        to greatly improve its performance of shaping, toughness, and        impact resistance, and make it much easier for hot pressing,        embossing, bending and carving    -   3. A smoke suppressant, calcium stearate powder, and flame        retardant are added to increase its performance of fire proof        and impact resistance, to reduce the density of smoke, and to        make it more ecofriendly.    -   4. This rigid polymer porous sheet is clearly the newest        formaldehyde free, eco-green, flame resistant and fireproof        building material.

Features and Usages of Rigid Polymer Filled Foam Material Sheet

1. Due to its lightweight, large range of density and flexibility, hardbody, and easy installation, it can be used in building materialindustry as a suitable eco green replacement for wood and engineeredwood materials such as but not limited to Framing Lumber, Plywood,Particle board, Oriented strand board (OSB) Type A,B,C, Medium densityfiberboard (MDF), High Density fiberboard (HDF), Glued laminated timber(glulam), Laminated veneer lumber (LVL), hardwood, Cross-LaminatedTimber (CLT), Structural Composite Lumber (SCL), Laminated strand lumber(LSL), Parallel strand lumber (PSL) 610, Timber, Finger-jointed lumber,High and Medium Density Overlay plywood (HDO and MDO). In suchapplications as but not limited to subflooring flooring, wall and roofsheathing ceiling and deck sheathing, lumber, timber, rafters, exteriorwall studs, purlins, headers, garage door headers, door jams, doors,crown moldings, batten moldings, rim boards, studs, columns, concreteforming, siding, mezzanine decks, and furniture; in addition intransportation industries such as for aircrafts as Aviation thermalacoustic insulation systems, as the roofs, bodies, and core layers ofships, cars, trucks, and trains. Many kinds of materials can be easilyadhered to its surface.

2. Due to its good performance of fire resistance andself-extinguishing, it can be used as fireproof doors, fire doors fillcore, I Joists (webs and flanges), roof trusses, ridge beams, floorbeams, lumber, sheathing board, sauna timber, flooring and furniture forhome usages, and in commercial buildings, hotels, and other publicareas. It can also be used in framing structures and as the main body ofarchaizing buildings and temples.

3. Due to its good performance of water-proof and moisture-proof, it canbe made into kitchen cabinets, bathroom fixtures, counter tops, andbathroom decoration materials. It is also a good choice for outdoorprojects, waterfront facilities, road and bridge projects, and templatesfor construction projects.

4. Due to its good anti-corrosion and termite proof performance, it is agood choice for industrial anti corrosion projects, industrialcontainers, industrial tanks, highway panels and archaizing buildingrepairing projects. It is also a good choice as flooring or subflooring, siding, wall assembly systems, and roof for home usages due toits high R value and waterproof characteristics.

5. As its surface can precede spray treatment, and due to its very lowthermal transfer and good thermal preservation, it can be used in walkin/free standing coolers, cold storage insulation board, refrigeratedbox truck bodies, refrigerated semi-tractor trailers, freezers, and asthe internal and external walls for hotels, and other buildings.

6. Due to its excellent insulating and flexibility properties, it can beused as thermal insulation lumber, thermal insulation sheets, thermalinsulation board, structural insulated panels, brick or stone insulationpanels, exterior insulation blocks, as the bodies of electricalappliances, bodies of outdoor transformers, and circuit insulationboards, etc.

7. The rigid polymer filled foam material sheet is created by hotpressing first followed by cold pressing, and it is easily carved; thusis well suited for use in melamine board, melamine flooring board,melamine cabinet board, polyboard laminate, cabinets, wall and ceilingdecoration board, embossed wall and ceiling decoration board, ceilingtiles, ceiling medallions, cloth veneer acoustic soft pack panel, clothveneer soundproof hard pack acoustic panel advertising boards, officefurniture, entertainment centers, embossed leather panel for video wallbackdrop screen, and hospital furniture.

FIG. 1a illustrates generally at 100 the process steps involved in thecreation of the rigid polymer filled foam material sheet. Thepolyurethane or rubber foam has a plurality of pores, which will befilled with a polymer during the process, as hereinafter described,thereby creating a rigid polymer filled foam material sheet. In thefirst step, the foam is cut to shape according to the desired productsize. In the second step, a mixture of polymers including one or more ofABS (Acrylonitrile Butadiene Styrene), PMMA (Poly methyl methacrylate)and PVC (Polyvinyl chloride) polymers is mixed with a solvent to createa slurry. Additional ingredients may include wood chips, fire retardantmaterials such as calcium silicate. The foam is completely covered withthe slurry and in one embodiment is allowed to dry. In the next step,the polymer covered foam is placed in a die of a heating and pressingmachine. Any solvent, if present, is evaporated quickly. ABS melts atabout 105° C., PMMA melts at about 165° C., and PVC melts at about 160°C. When the mold is heated to temperatures below 170° C., all thepolymeric ingredients are softened. Thus, during the heating process,the polymer slurry composition densifies to a porous sheet structure.When the densification is complete after a selected process time, therigid polymer porous material sheet may be removed from the mold.

PVC has a large amount of chlorine and when the rigid polymer filledfoam material sheet is exposed to flame, the degradation of PVC releasesa large amount of chlorine that extinguishes the flame and therebyprovides fire retardant properties to the rigid polymer filled foammaterial sheet.

FIG. 1b illustrates a graph showing the relationship between theFikentacher K value and the molecular weight of PVC polymers.Preferably, the polyvinylchloride used in the present invention is inthe form of 100 to 150 micrometer particles produced by suspension oremulsion polymerization. The K value of the polyvinylchloridehomopolymer or copolymer with polyvinyl acetate has a K value greaterthan 65 representing a molecular weight of 60,000 as shown in the graphbelow reproduced from PVC Plastics by W. V. Titow. A K value of 50 is alow molecular weight soft PVC while a K value of 80 is a high molecularweight strong PVC.

FIG. 2 illustrates generally at 200 a micrograph of the rigid polymerporous material sheet. The millimeter marker is shown in the figure.Individual air cells of the porous polymer sheet are clearly seen. Thissample is sample A, which had a dimension of 25 cm length. 13 an widthand 1.2 an in thickness with a volume of 390 cc and weighed 77 grams.Thus the density of this sample A is 0.197 gm/cc.

FIG. 3 illustrates generally at 300 the method used for measuring thethermal conductivity of the sheet. The subject sheet can be made intodifferent hardness for different Industries, and different Industrialend uses and applications. The formula can be adjusted to fit virtuallyany Industrial application or end use. Heat flow meter testing inaccordance with ASTM C518 was conducted on 0.145 gm/cc and 0.165 gm/ccdensity specimens with varying thicknesses resulting in R values (seebelow). Chambers 301 and 302 are maintained at different temperaturesand heat flow is measured.

ASTM C518-10 .145 gm/cc .165 gm/cc R Value (½″thick) 2.00 1.96 (¾″thick)3.04 2.94 (1″thick) 4.01 3.90 (1½″thick) 6.05 5.86

The subject invention's samples were found to have superior per inch RValue insulation properties to Fiberglass. Yet also exhibits vastlydifferent material properties and attributes.

*Testing Results ASTM C518-10 (above)

The measured thermal properties and the R values of the differentthickness specimens are shown as a comparative basis as compared toother commonly available construction materials.

Subject Invention vs. Common Building Material with Identical ThicknessR-Value Comparison

Subject Invention Material: Common Foaming Board Building/SheathingBuilding Material .145 gm/cc .165 gm/cc Board Thickness R-Value R-ValueR-Value Gypsum Wall ½″ 0.45 2.00 1.96 Board Plywood ½″ 0.62 2.00 1.96Plywood ¾″ 0.94 3.04 2.94 Plywood 1″ 1.25 4.01 3.90 Fiber board ½″ 1.322.00 1.96 sheathing Fiber board 1″ 2.64 4.01 3.90 sheathing MediumDensity ½″ 0.53 2.00 1.96 Particle Board Fiberglass ¾″ 3.00 3.04 2.94sheathing Fiberglass 1″ 4.00 4.01 3.90 sheathing Fiberglass 1½″ 6.006.05 5.86 sheathing

Subject Invention Common Foaming Board Building Material .145 gm/ .165gm/ Material: Insulating Materials R- cc cc (Per 1 inch Thickness)Thickness Value R-Value R-Value Fiberglass Batt 1″ 3.14 4.01 3.90Fiberglass Blown (Attic) 1″ 2.20 4.01 3.90 Fiberglass Blown (Wall) 1″3.20 4.01 3.90 Rock Wool Batt 1″ 3.14 4.01 3.90 Rock Wool Blown (Attic)1″ 3.10 4.01 3.90 Rock Wool Blown (Wall) 1″ 3.03 4.01 3.90 CellulousBlown (Attic) 1″ 3.13 4.01 3.90 Cellulous Blown (Wall) 1″ 3.70 4.01 3.90Vermiculite 1″ 2.13 4.01 3.90 Autoclaved Aerated Concrete 1″ 3.90 4.013.90 Urea Terpolymer Foam 1″ 4.48 4.01 3.90 Rigid Fiberglass (>4 lb/ft3)1″ 4.00 4.01 3.90 Expanded Polystyrene 1″ 4.00 4.01 3.90 (Beadboard)Extruded Polystyrene 1″ 5.00 4.01 3.90 Polyurethane 1″ 6.00 4.01 3.90(foamed-in-place) Foil Faced Polyisocyanurate 1″ 6.00 4.01 3.90

Common Subject Invention Building Foaming Board Material .145 gm/cc .165gm/cc Material: Siding Thickness R-Value R-Value R-Value Hardboard ½″0.34 2.00 1.96 Plywood ½″ 0.62 2.00 1.96 Plywood ¾″ 0.93 3.04 2.94 WoodBevel Lapped 0.80 3.04 2.94 Aluminum/Steel/Vinyl 0.61 3.04 2.94 (notinsulated) Aluminum/Steel/Vinyl 1.80 3.04 2.94 (½″ insulation)

Subject Invention Foaming Material: Common Building Board InteriorFinish Material .145 gm/cc .165 gm/cc Materials Thickness R-ValueR-Value R-Value Gypsum Board ½″ 0.45 2.00 1.96 (Drywall) Paneling ¼″0.31 1.00 1.00 Paneling ½″ 2.00 1.96 Paneling ¾″ 3.04 2.94 Paneling 1″4.01 3.90

Common Subject Invention Building Foaming Board Material: Material .145gm/cc .165 gm/cc Flooring Materials Thickness R-Value R-Value R-ValuePlywood ¾″ 0.94 3.04 2.94 Plywood 1″ 1.25 4.01 3.90 Particle Board 1″1.31 4.01 3.90 (underlayment) Hardwood Flooring ¾″ 0.68 3.04 2.94Hardwood Flooring 1″ 0.91 4.01 3.90 Tile, Linoleum 0.05 2.00 1.96 OSBInsulated 2″ 7.00 8.02 7.80 Subfloor Panel System

Common Subject Invention Building Foaming Board Material .145 gm/cc .165gm/cc Material: Doors Thickness R-Value R-Value R-Value Wood Hollow Core1¾″ 2.17 7.05 6.84 Flush Wood Solid core Flush 1¾″ 3.03 7.05 6.84 WoodSolid core Flush 2¼″ 3.70 9.02 8.80 Insulated metal door 2″ 15.00 8.027.80 (2″ w/urethane)

In all cases, the sheet of the present invention provides better Rvalues as compared to any of the commercially available constructionmaterial. The sheet of the present invention is also Fire Proof, WaterProof (water absorption 0.81%), Termite Proof, Sound Proof, Acid Proof,and is the next state of the art Eco Green Building Material comprisedof 100% Formaldehyde Free components.

Sound/Acoustic properties are set forth below:

Acoustical Performance Test Report: Density 0.145 gm/cc and 0.165 gm/cc

Tube Diameter: 57 mm

Impedance tube tests were performed on Density 0.145 gm/cc and 0.165gm/cc samples. Three test specimens were provided for each. Test methodswere conducted in accordance with ASTM E1050-12, Standard Test Methodfor Impedance and Absorption of Acoustical Materials Using a Tube, TwoMicrophones and A Digital Frequency Analysis System. Instrumentationused is set forth below.

Instrumentation:

ATI Date of Instrument Manufacturer Model Description Number CalibrationAnalyzer Aglient 35670A Environmental Noise Analyzer Y002929 June 2013*Microphone One G.R.A.S Type 40 AR ½″, pressure type, condenser 063359September 2014 microphone Microphone One Preamp G.R.A.S Type 26 AK ½″,preamplifier Y003251 September 2014 Microphone Two G.R.A.S Type 40 AR½″, pressure type, condenser Y003245 September 2014 microphoneMicrophone Two Preamp G.R.A.S Type 26 AK ½″, peramplifier Y003248September 2014 Microphone Calibrator Larson Davis CAL 200 PistonphoneCalibrator 065327 September 2014 Driver JBL 2426H Compression Driver005719 N/A Equalizer Rane RPE 228 Digital equalizer 005081 N/A Weatherstation Davis 615 C. Weather station Y003257 July 2014 57 min ImpedanceTube Architectural Testing, Inc. N/A 57 mm Impedance tube with 005712N/A microphone holder, stand, and acrylic sample holder with plunger*Now: The calibration frequency for this equipment is every two yearsper the manufacturer's recommendation.

Signal Processing Parameters:

Frequency Resolution 1600 Lines Frequency Span 3200 Hertz Averaging TypeRMS Number of Averages 25 Windowing Function Hanning Window Overlap66.70%

N/A—Non Applicable

Each specimen was installed flush with the open end of the specimenholder. Any gaps that existed between the specimen and holder weresealed with petroleum jelly. The holder was installed onto the open endof the impedance tube. Random noise was generated in the tube, andmeasurements were conducted and averaged. The air temperature, relativehumidity and atmospheric pressure conditions were monitored and recordedduring the test measurements. The results for the specimens wereaveraged. The r/pc, x/pc, gpc, bpc and the normal incidence soundabsorption coefficients were calculated.

Density 0.145 gm/cc:

Specimen Description Thickness (cm) Weight (g) A Foam board 1.875 7.529B Foam board 1.920 7.560 C Foam board 1.915 7.560Density 0.165 gm/cc:

Specimen Description Thickness (cm) Weight (g) A Foam board 2.017 24.012B Foam board 2.019 24.591 C Foam board 2.019 24.560

ASTM E1050 .145 gm/cc .165 gm/cc Acoustic 0.03-0.17 (250-2000 hz)0.03-0.05 (250-2000 hz) Absorption No Absorption No AbsorptionDensity 0.145 gm/cc:

Summary of Test Results ⅓ Octave Normal Incidence Sound AbsorptionCoefficients at the Octave Band Frequencies Data File No. 63 125 250 5001000 2000 4000 E7935.01 N/A N/A 0.03 0.03 0.05 0.17 N/A N/A indicatesthe frequency is not applicable to the respective tube diameter.Density 0.165 gm/cc

Summary of Test Results ⅓ Octave Normal Incidence Sound AbsorptionCoefficients at the Octave Band Frequencies Data File No. 63 125 250 5001000 2000 4000 E7255.01A N/A N/A 0.03 0.03 0.02 0.05 N/A N/A indicatesthe frequency is not applicable to the respective tube diameter.Physical properties of the samples were determined, as set forth below0.145 gm/cc density:

ASTM D 635 PASS - Failure to sustain burn Rate of Burn corresponds to aCC1/HB classification. ASTM C 367 281 LBF Average Hardness ASTM C 3670.05 Average Mass Loss Friability ASTM C 367 Average Sag 0.033 Sag TestAve Recovery 0.037 *conditioning for 17 hours at 32° C. and 90% relativehumidity *6 hour “wet” recovery period at 23° C. and 50% relativehumidity ASTM C367 Machine Cross Transverse Direction Direction StrengthAverage Average Width 3.082 3.085 Depth 0.0754 0.0751 Max Load (lbf)33.8 32.4 Max Deflection (in) 3.502 3.598 (Maximum range of Testingmachine capability) Modulus of 347 335 Rupture (psi)

The subject foaming boards can be manufactured into standard buildingboard size, and any standard lumber size specification. For example, themolds and machinery to form the foaming boards are typically availablein standard size of 1220 mm×2440 mm (48 inch×96 inch). Therefore thevariance is the thickness of the mold, which in turn produces differentthicknesses of slab. Once the finished slab has been removed from themold, the board can be cut into building board sizes or lumber sizesaccording to needs and applications.

FIG. 4 illustrates at 400 the harness measurement of the rigid polymerporous sheet having 0.145 gm/cc density according to ASTM C 36. Thefigure shows the test set up and the indentation. Hardness test wasconducted on five 4 in. by 4 in. specimen. A compressive load wasapplied to each specimen utilizing an Instron Universal Testing Machine(ICN: 005741) through a 2 in. diameter ball at a rate of 0.10 in/minuntil a sample penetration of 0.250 in was achieved.

Hardness Results

.145 gm/cc density Thickness (in.) Hardness (lbf) Average 0.7542 281

ASTM C 367—Transverse Strength tests were conducted. Five, 3 in. by 14in. by 0.750 in. specimen having a density of 0.145 gm/cc were cut fromthe submitted panels in a machine direction, and another five were cutin the cross direction. Test specimen dimensions were measured using a12 inch (by 0.001 inch) digital caliper (ICN: 004722). Specimens wereindividually mounted in an Instron Model 3369 Universal Testing Machine(ICN: 005740) using a three-point flexural loading setup. Test specimenswere supported at a span of 12 in. The diameter of the loading nose andthe support rods were 1.25 in. The specimens were loaded at a rate of0.50 in/min until either peak load was achieved or a deflection of 3.5in. was reached. As illustrated by FIG. 5, the specimens exhibitedexcellent flexibility exceeding 110°. Midspan deflection wascontinuously recorded during the loading process using the crossheadmovement of the test machine.

Transverse Strength Results

Maximum Modulus of MD Maximum Deflection Rupture results Width (in)Depth (in) Load (lbf) (in) (psi) Average 3.082 0.754 33.8 3.502 347

Maximum Modulus of CD Maximum Deflection Rupture results Width (in)Depth (in) Load (lbf) (in) (psi) Average 3.085 0.751 32.4 3.598 335

ASTM C 367—Friability tests were conducted. Twelve, 1 in. by 1 in. by0.750 in. specimens were weighed using a Mettler Toledo analyticalbalance (ICN: 003449) and placed within the oak friability tumbler alongwith twenty four, ¾″ oak cubes. The tumbler was closed to prevent thetest materials from being ejected and the tumbler was rotated around itsaxis at a rate of 60 rpm for 10 minutes. The sample set was then removedfrom the tumbler and weighed for mass loss. They were then reinsertedinto the tumbler without the previous debris being removed, and themechanism operated for 10 additional minutes. At the conclusion of thesecond 10 minutes, the samples were removed and reweighed, resulting ina final mass loss.

Friability Test Results

10 Minute Mass Loss Next 10 min Mass Loss Initial weight Weight (g) (%)weight(g) (%) Average 2.1824 2.1813 0.05% 2.1801 0.11

FIG. 5 illustrates at 500 the bending of the rigid polymer porous sheet.The sample is reversibly bent to 110° without cracks. It represents theonly building board used for drywall, or wall assembly sheathing thatcan flex to an angle exceeding 120 degrees and then return to itsoriginal shape without any breaking, cracking or exterior flawing in itsappearance or rigidity.

Other test samples marked Sample B had a dimension of 25 cm length. 15cm width and 2 cm in thickness with a volume of 750 cc and weighed 275grams. Thus the density of this sample B is 0.367 gm/cc. A third sample,Sample C had a dimension of 24.5 cm length. 12 cm width and 0.5 cm inthickness with a volume of 147 cc and weighed 275 grams. Thus thedensity of this sample C is 0.558 gm/cc. Clearly the rigid polymerporous sheet fabrication process such as the amount of slurry addedduring molding of the sheet, the temperature of the mold and thepressure applied determines the density. In addition, the presence ofdecorative structure on the sheet increases both the hardness and thedensity of the sheet formed.

Wall Assembly Systems—Foaming Board Composite Wall Assembly Systems andFoaming Board Related Products of the subject invention eliminates orgreatly reduces “Thermal Bridging” and “Framing Factor” to the wallassembly and achieves a 114.33% increase in R-Value (using CaliforniaEnergy Commission of 25% framing factor) throughout the entire wallassembly system and building envelope creating a thermal break anduniform increase in thermal resistance.

A thermal bridge, also called a cold bridge, is an unwanted path forheat flow that bypasses the main insulation of a building envelope. Athermal bridge is a fundamental of heat transfer where a penetration ofthe insulation layer by a highly conductive or non-insulating materialtakes place in the separation between the interior (or conditionedspace) and exterior environments of a building assembly (also known asthe building enclosure, building envelope, or thermal envelope). Placinga good conductor in parallel with good insulation is often referred toas “thermal bridging” because it provides a path for heat flow thatbypasses the main insulation.

Energy loss inside the building envelope occurs by two forces conductionand convection. Conduction is the transfer of heat through a solidmaterial, which is what insulation is designed to prevent, and isresponsible for 60 percent of heat or cooling loss in the average home.Convection is the transfer of air through gaps in the walls and roof ofthe home. Outside air leaking into the home or air infiltration, isresponsible for 40 percent of heat or cooling loss in the average home.

Wood-framed homes rely on dimensional lumber, referred to as studs, atregular intervals to provide structural support. Lumber is a very poorinsulator and forms a thermal bridge from the outside of the home to theinside of the home where heat can pass through by conduction. DoorFraming, steel studs, and wood or metal window frames are also commonthermal bridges.

Insulation around a thermal bridge is of little help in preventing heatloss or gain due to thermal bridging; the bridging has to be eliminated,rebuilt with a reduced cross-section or with materials that have betterinsulating properties, or with a section of material with low thermalconductivity installed between metal components to retard the passage ofheat through a wall or window assembly, called a thermal break.

FIGS. 6a and 6b illustrate the thermal bridge and energy lost throughstuds. FIGS. 7a and 7b illustrate the framing factor concept.

Foaming Board Composite Wall Assembly Systems and Foaming Board relatedproducts comprising the subject inventive material create a thermalbreak in the thermal bridging occurring in wall assemblies of thebuilding envelope resulting in a 114.33% increase in R-Value wallassembly system and building envelope. (See Wall Assembly R-ValueBelow).

Calculating Assembly Wall R-Value* (Standard 2×4 Wall Assembly) *Thisexample is just for wood frame construction. Steel studs are a morecomplex calculation Formula: Assembly R-Value−1/(AssemblyU-Value)−1/(U-studs x %+U-cavity x %)

Common Building Material Subject Invention R-Value R-Value AssemblyR-Value R-Value Assembly component Studs Cavity R-Value Studs CavityR-Value Wall-Outside Air 0.17 0.17 0.17 0.17 Film (Winter) Siding - Wood0.80 0.80 3.96 3.96 Bevel (½″.145 gm/cc + ½″ .165 gm/cc) Plywood 0.630.63 3.93 3.93 (1″ Sheathing (½) thick .165 gm/cc) 3½ Fiberglass 13.0013.00  Bart 3½″ Stud 4.38 13.65 (3.5″ × 3.90 .165 gm/cc) ½″ Drywall 0.450.45 3.96 3.96 (1″thick .165 gm/cc) Inside Air Film 0.68 0.68 0.68 0.68Percent for 25% 75% 25% 75% 16″O.C. + Additional Studs{circumflex over( )} Total Wall 7.11 15.73 26.35 25.70  Component R- Value WallComponent 0.1406 0.0636 0.0379  0.0389 U-Value Total Wall 12.07 25.87Assembly R- Value (California Dept. Energy 25% framing factor)

California Energy Standard Subject Percent increase in Commission WallInvention Wall Assembly R- (25% Framing Factor) R-Value R-Value Value12.07 25.87 25.87 − 12.07 = 13.80 (13.80/12.07) × 100 = 114.33% *Foaming board wall assembly systems using the subject inventive materialresult in an increase in total wall assembly R-value from 12.07 to 25.87which is an increase of 114.33%.

The foaming board composite wall assembly systems and foaming boardrelated products of the subject invention eliminates or reduces to ameasurable insignificant fraction thermal bridging and framing factor inthe building envelope by applying its composite materials with superiorindustry leading R-Values to achieve a uniform thermal resistancethroughout the entire wall assembly system.

The term “framing factor” is widely used to express a percent of thetotal wall area occupied by framing members. The extent to which a wall,roof or floor's framing reduces the R-value of its insulation is calledits “framing factor”. It is simply a percentage reduction in R-valuewhen thermal bridging occurs and a heal flow is created by conductionthrough the wood or steel frame of a building envelope. The more framingmembers in a wall structure, the higher the framing factor. Steel studassemblies often have framing factors of 50% and above, while woodframing is usually closer to 25%. For example, a wall with R-20insulation and a framing factor of 25% would have an overall insulationvalue of R-15.

According to a 2002 Report framing factors up to 27% can be found inresidential walls in California in 2001. In 2003 a study by ASHRAE foundan average of 25% framing factor for U.S. Homes. The result of thesestudies demonstrated significant sensitivity in some configurations ofresidential walls to the framing factor and insulation imperfections.

In keeping with the Energy modal Engineering report for the CaliforniaEnergy Commission, ALL wall assemblies in this report have framingfactors of approximately 27% (1). It is well known that a presence offraming members (like wood or steel profiles) reduces the R-Value of awall system. The measure of this effect is known as the framing factorcoefficient ‘F’ of a wall, which is calculated using the followingsimple expression that contains clear-wall R-Value, Rcw, and thecenter-of-cavity R-Value, R n: f=[1−Rcw/Rn]*100.

The subject invention density 0.145 gm/co is the only building boardthat can flex to an angle exceeding 130 degrees and then return to itsoriginal shape without any breaking, cracking or exterior flawing in itsappearance or rigidity. (0.145 gm/cc density) Some concrete flexiblecement board is available on the market. However, flexible cement boardcan only flex approximately 20 degrees and is not a thermal insulator.Foaming Board of the subject invention is the leading insulator with amultitude of applications and flexibility that is unmatched in thebuilding material industry.

Eagle America Framing System—Common Wood and Engineered lumber arespecifically prone to humidity induced water absorption resulting inBuckling, Crowning, and Cupping of panels and flooring when no space forhumidity expansion is allotted for. Light-frame construction using“platform framing” and standardized dimensional lumber has become thedominant construction method in North America. Such light-framestructures usually gain strength from rigid panels (plywood and otherplywood-like composites such as oriented strand board (OSB). However,due to humidity swelling properties of common and engineered wood, a “⅛”installation gap allowance for wood swelling” must be inserted betweenpanels when installing subfloors, floors, walls, ceilings, and roofs inthe framed structure.

The present invention was humidity conditioned under ASTM C 367 humiditytest for 17 hours at 32° C. and 90% relative humidity, and then a 6 hour“wet” recovery period at 23° C. and 50% relative humidity at 145.28kg/m3 density. Resulting in deflection of 0.033 of an inch at 90%humidity, and recovery of 0.037 of an inch when reduced to 50% relativehumidity.

The present invention's minimal water absorption is in direct oppositionto common and engineered wood building material attributes, andeliminates the need for the “⅛” installation gap allowance for woodswelling between panels when installing subfloors, floors, walls,ceilings, and roofs in a framed structure, and eliminates subsequentbuilding defects associated with humidity swelling.

The elimination of the “⅛” gap creates an entirely new method of framingconstruction, and is known as “The Eagle America Framing System.”

The “Eagle America Framing System” of present invention differentiatesitself from common building materials, and standard “platform” framingconstruction by elimination of the ⅛″ gap allowance for wood swelling.When assembled in accordance with present invention, said panels can bebutted flush against each other increasing the overall structuralstability. In addition, the system effectively seals the structure frommoisture, air penetration and natural air drafts, eliminates pestpathways, increases the overall strength of the framed structure, andeliminates or reduces to a measurably insignificant fraction energy lossfrom thermal bridging due to (i) the elimination of the ⅛″ gap, and (ii)the increased thermal insulation properties of present invention insheet or lumber form verses common wood and wood related buildingmaterials.

Having thus described the invention in rather full detail, it will beunderstood that such detail need not be strictly adhered to, but thatadditional changes and modifications may suggest themselves to oneskilled in the art, all falling within the scope of the invention asdefined by the subjoined claims.

What is claimed is:
 1. A rigid polyvinylchloride based polymer porousmaterial sheet, comprising: a) a polymer mixture of ultrafine particlesof polyvinylchloride, a non-phthalate plasticizer, a foaming agent thathas a decomposition temperature very close to the softening point ofsaid ultrafine particles of polyvinylchloride, and a thermal stabilizer;b) said rigid polyvinylchloride based polymer porous material sheetbeing plain or having decorative structure; c) said rigidpolyvinylchloride based polymer porous material sheet havingapproximately 0.16 to 0.66 grams/cc or overall density of about 10% to40% of solid PVC; d) closed cell air pockets uniformly distributedthroughout said rigid polyvinylchloride based polymer porous materialsheet; whereby said closed cell air pockets provide enhanced thermalresistance and sound attenuation properties for use in buildingconstruction, aviation or other industries, and decorative applications.2. The rigid polyvinylchloride based polymer porous material sheet asrecited by claim 1, wherein said polyvinylchloride based composition ofultrafine particles comprises polyvinyl acetate in amounts ranging from2 to 30%.
 3. The rigid polyvinylchloride based polymer porous materialsheet as recited by claim 1, wherein said non phthalate plasticizer isdiisononyl 1,2-cyclohexanedicarboxylate (DINCH).
 4. The rigidpolyvinylchloride based polymer porous material sheet as recited byclaim 1, wherein said foaming agent is azodicarbonamide.
 5. The rigidpolyvinylchloride based polymer porous material sheet as recited byclaim 1, wherein said slurry has propyl alcohol wetting said ultrafineparticles.
 6. The rigid polyvinylchloride based polymer porous materialsheet as recited by claim 1, wherein said slurry has anionic surfactantin an aqueous medium wetting said ultrafine particles.
 7. The rigidpolyvinylchloride based polymer porous material sheet as recited byclaim 1, wherein said polymer mixture additionally includes wood chipand fire retardant chemicals.
 8. The rigid polyvinylchloride basedpolymer porous material sheet as recited by claim 7, wherein said fireretardant chemical is calcium silicate.
 9. The rigid polyvinylchloridebased polymer porous material sheet as recited by claim 1, said sheetbeing suitable for use as a wall board, sheathing board, interiorfinishing board, subflooring, flooring, wall and roof sheathing, ceilingand deck sheathing , lumber, timber, rafters, exterior wall studs,purlins, headers, ridge beams, floor beams, garage door headers, IJoists (webs and flanges), roof trusses, door jams, doors, crownmoldings, batten moldings, rim boards, studs, columns, concrete forming,siding, sauna timber, furniture, office furniture, entertainmentcenters, mezzanine decks, melamine board, melamine flooring board,melamine cabinet board, polyboard laminate, cabinets, furniture, ceilingtiles, ceiling medallions, cloth veneer acoustic soft pack panel, clothveneer soundproof hard pack acoustic panel, wall and ceiling decorationboard, embossed wall and ceiling decoration board, bathroom fixtures,counter tops, fire doors fill core, embossed leather panel for videowall backdrop screen, marine and boat applications, automotive and trainapplications, industrial containers, industrial tanks, refrigerated boxtruck bodies, refrigerated tractor trailer, Aviation thermal acousticinsulation systems, framing structures and in wall assembly systems dueto its increased thermal insulation properties and bend properties. 10.The method of forming rigid polymer porous material sheet as recited inclaim 9 wherein the polymer slurry is dried after being fed to the moldand prior to application of heat and pressure.
 11. A wall assemblysystem comprising the rigid polymer porous lumber formed by the methodof claim
 9. 12. The rigid polyvinyl chloride based polymer porousmaterial sheet as recited by claim 1, said sheet being suitable for useas a flooring material, thermal insulation lumber, thermal insulationsheets, thermal insulation board, brick or stone insulation panels,exterior insulation blocks, structural insulated panels, walk in/freestanding coolers, cold storage insulation board, and siding due to itsincreased thermal insulation properties.
 13. The rigid polyvinylchloride based polymer porous material sheet as recited by claim 1, saidsheet being suitable for use as a building board or lumber due to itsincreased strength, bend capability and thermal insulation properties.14. The rigid polyvinylchloride based polymer porous material sheet asrecited by claim 1, said sheet being suitable for use as a door, highwaypanels, and in window and door framing due to its increased strength,bend capability, paintability and thermal insulation properties.
 15. Awall assembly system comprising the rigid polymer porous material sheetrecited by claim
 1. 16. A wall assembly system comprising the rigidpolymer porous material sheet as recited by claim 1, wherein said sheethas a thickness ranging between ½-1 ½ and an R-Value ranging between1.96 to 6.05.
 17. A wall assembly system comprising the rigid polymerporous material sheet as recited by claim 1, wherein said sheet is usedin aeronautic acoustic thermal insulation systems.